JP2000216415A - Solar cell module, its manufacture and working method, and solar battery power generation system using the solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a solar cell module excellent in durability, reliability, and external appearance. SOLUTION: In a solar cell module having an electrode leading-out part constituted of conducting members 108a, 108b for introducing electric power from a photovoltaic device to the outside, the conducting members 108a, 108b are constituted of covered wires coated with organic polymer resin having a softening temperature lower than or equal to a heating temperature in the manufacturing process of the solar cell module after the conducting members are fixed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module which has high reliability in bending and has good appearance with little unevenness in wiring and the like.
The present invention relates to a building material-integrated solar cell module such as a roofing material having excellent design properties, and a flexible solar cell module that can be bent freely.

[0002]

2. Description of the Related Art In recent years, awareness of protection of energy resources and environmental issues has been increasing worldwide. In particular, there is a serious concern about the depletion of petroleum and the like and the global warming phenomenon associated with CO ₂ emission. Therefore, great expectations are placed on solar cell energy, which is a clean energy capable of directly converting solar energy into electric power.

The types of solar cells widely used at present include those using crystalline silicon and those using amorphous silicon.

Since an amorphous silicon solar cell can continuously form a semiconductor photoactive layer having a larger area than a crystalline silicon solar cell, the manufacturing process is simple, the manufacturing energy is reduced, and the manufacturing cost is reduced. Can be.
Further, since the thickness of the photovoltaic element is as thin as about 1/1000 of that of the crystalline silicon solar cell, the cost of raw materials can be reduced, and an inexpensive solar cell module can be obtained. Further, when an amorphous silicon layer is formed on a flexible substrate such as a thin stainless steel or a film, a flexible and lightweight solar cell module can be obtained.

[0005] In recent years, a solar cell module integrated with building materials has been put to practical use, taking advantage of the advantages of an amorphous silicon solar cell having a large area, low cost, and light weight. In particular, there is a great demand for a solar cell module integrated with a roofing material. . In this case, a reinforcing plate such as a steel plate is attached to the back surface to increase the mechanical strength so that it can be used as a building material.

Conventionally, when a solar cell module is installed on a roof, a process is performed in which a frame is attached to the solar cell module, a gantry is installed on the roof, and the solar cell module is installed thereon. I was
On the other hand, a roof material-integrated solar cell module to which a reinforcing plate is attached can be directly installed as a roof material by bending the reinforcing plate. That is,
Since the cost of raw materials such as a gantry and the number of construction steps are reduced, a solar cell module with lower cost can be provided. In addition, since a stand is not required, the roof becomes a lightweight roof, and the building has excellent earthquake resistance.

As a method of extracting the electric power generated by these solar cell modules, it is common to provide an electrode extraction section on the back side of the solar cell module. Since this electrode take-out part is a part for taking out the electric power generated by the solar cell module to the outside by a lead wire, a cable, etc., it reliably protects it from damage and the like, and ensures insulation as a waterproof structure. Therefore, a terminal box or the like is often provided on the back side of the solar cell module.

[0008] Applications other than building material-integrated solar cell modules include, for example, those used in camping and the like.
There is a need for portable and lightweight solar cell modules. That is, it is possible to follow a free shape without providing a reinforcing plate on the back surface, and a light-weight solar cell module has been put to practical use.

The problems of the conventional roofing-integrated solar cell module will be described below with reference to FIG.

FIG. 8 is a perspective view of a conventional solar cell module viewed from the non-light-receiving surface side.

As shown in FIG. 8, in a conventional general roofing-material-integrated solar cell module 801, a terminal box 802 is provided on the back side thereof. Therefore, it is necessary to raise the height so that the terminal box does not hit the ground board.

That is, one unnecessary step is added to the general roof, and the workability is reduced. Therefore, it has been considered that the electrodes are taken out from the side of the solar cell module and no terminal box is provided on the back side.
For example, in Japanese Patent Application Laid-Open No. 8-186280, at the same position on both sides of the solar cell module, a female connector for the plus side is provided on one side, and a male connector for the minus side is provided on the other side. Is disclosed. However, the terminal box is still attached to the back side, and a gantry, a pier, and the like are required.

When a roofing-integrated solar cell module is used, a reinforcing material larger than the photovoltaic element is attached to the back surface, and a reinforcing material portion without a photovoltaic element (a margin portion) is processed. By forming a fitting part etc.
The method of constructing as a roof is taken.

When the electrodes are taken out from the side, the electrode taking-out conductive members (electric wires) 108a, 108
b is drawn out to the outside through the margin portion. That is, the conductive member 108 for taking out the electrode
a and 108b are also bent together with the reinforcing material.
Generally, conductive members 108a and 108b for taking out electrodes
In such a case, a complicated bending process may cause a crack in the copper foil. Since the electric power generated by the solar cell module is extracted to the outside through this conductive member, it is a very serious problem that the reliability of this part cannot be maintained.

Further, in the bent portion, a force such as a contraction stress or a tensile stress is applied. When the solar cell module is used in a bent state, the interface between the resin of the coating material and the copper foil is generated in these places. Peeling occurred in some cases.
Thus, when a peeling interface is generated and a void is formed, moisture accumulates in the void during long-term use. In particular, if such a phenomenon occurs in the conductive member portion which is a current collecting portion, the reliability is reduced.

Furthermore, when the most common ethylene-vinyl acetate copolymer (EVA) is used as the coating resin of the solar cell module, the discoloration of copper occurs when the copper foil and EVA are in contact with each other. , Corrosion and discoloration and deterioration of EVA. This phenomenon is attributed to the accelerated degradation of EVA due to environmental factors such as light, heat, and moisture and the catalytic action of copper, and the corrosion of copper by acetic acid, which is a decomposition product of EVA, or the synergistic action of these. Conceivable. That is, when copper foil is used as the conductive member,
It is difficult to ensure reliability.

[0017]

As a method for solving the above-mentioned problem, it is conceivable to use a coated conductor as an electrode instead of a copper foil. However, since the covered conductor is thicker than the copper foil, after the photovoltaic element module and the covered conductor are resin-sealed, the shape of the covered conductor can be clearly confirmed as unevenness from the light receiving surface side. The presence of such irregularities is inferior in aesthetics, and is particularly problematic when using a solar cell module as a building material. In addition, if there is a portion that is only partially convex, it is also weak against scratching from the outside. Further, even if a coated conductor is used, it is not possible to prevent the occurrence of peeling at the interface between the resin and the electric wire, and there remains a problem in reliability.

Therefore, in the present invention, it is necessary to solve the following problems.

(1) If bending is performed at a location including an electrode portion, a crack is formed in the electrode at that portion, which causes a problem in reliability.

(2) Peeling may occur at the interface between the resin of the coating material and the copper foil.

(3) When a metal member, particularly copper, is used as the electrode, the copper and the resin are discolored, corroded, deteriorated, etc. due to a synergistic action with the resin.

(4) When a covered conductor is used, the electrode has large irregularities and is inferior in aesthetics.

(5) In the case of using a covered conductor, the scratch resistance is lowered at the protruding portion, which is the protrusion of the electric wire.

The present invention has been proposed in view of the above-mentioned circumstances, and has as its object to provide a solar cell module having high durability, excellent reliability, and excellent aesthetics.

It is another object of the present invention to provide a method for manufacturing and constructing such a solar cell module.

Another object is to provide a solar cell power generation system using such a solar cell module.

[0027]

Means for Solving the Problems As a result of intensive research and development to solve the above-mentioned problems, the present inventor has found that the following solar cell module is the best.

That is, the solar cell module of the present invention is a solar cell module having an electrode take-out portion constituted by a conductive member for deriving electric power from the photovoltaic element to the outside, or the photovoltaic element is electrically conductive. In a solar cell module having a photovoltaic element module connected by members, the conductive member is coated with an organic polymer resin having a softening temperature equal to or lower than a heating temperature in a solar cell module manufacturing process after being attached. It is a covered conductor.

In the solar cell module, the organic polymer resin preferably has a softening temperature of 200 ° C. or less.

In the solar cell module, the organic polymer resin is preferably made of a thermoplastic resin.

In the solar cell module, the organic polymer resin is vinyl chloride, heat-resistant vinyl chloride, polyethylene, foamed polyethylene, polyurethane, polypropylene, polyvinylidene fluoride, polysulfone, ethylene-vinyl acetate copolymer, ethylene propylene. Any of copolymer blends, or natural rubber, styrene rubber, butadiene rubber, chloroprene rubber, polyethylene chlorosulfonate, polyethylene chloride, butyl rubber,
The rubber is preferably any of ethylene acrylate rubbers.

In the solar cell module, the heating temperature in the manufacturing process of the solar cell module is 30
It is preferably 0 ° C. or lower.

In the solar cell module, it is preferable that the conductive portion of the coated conductive wire is any of soft copper, nickel, tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, and aluminum-plated soft copper.

In the solar cell module, it is preferable that a plurality of the photovoltaic elements are connected to form a photovoltaic element module.

In the solar cell module, it is preferable that the photovoltaic element or the photovoltaic element module and the conductive member are simultaneously sealed with a resin.

In the solar cell module, it is preferable that pressurization and heating are performed simultaneously in the resin sealing step of the solar cell module.

In the above-mentioned solar cell module, it is preferable that the solar cell module uses a translucent resin film as the outermost translucent surface member.

In the solar cell module, it is preferable that a reinforcing plate is provided on the rearmost side of the solar cell module.

In the solar cell module, it is preferable to provide a resin film layer as a back surface member on the rearmost surface side of the solar cell module.

The method for manufacturing a solar cell module according to the present invention is the same as the method for manufacturing a solar cell module having an electrode lead-out portion constituted by a conductive member for leading electric power to the outside from a photovoltaic element. In the method for manufacturing a solar cell module in which a power element is connected by a conductive member and a photovoltaic element module is used, a coated conductive wire coated with an organic polymer resin is used as the conductive member, after the coated conductive wire is attached. And heating the solar cell module at a temperature equal to or higher than the softening temperature of the organic polymer resin.

According to the solar cell module construction method of the present invention, each of the solar cell modules having the above-described features is
It is characterized in that it is fixed on a field board by a fixing member and adjacent building materials are fixed to each other.

A solar cell power generation system using a solar cell module according to the present invention is characterized by having each solar cell module having the above-mentioned features and a power converter connected to each solar cell module. It is.

The solar cell module of the present invention, the method of manufacturing the solar cell module, the method of construction, and the solar cell power generation system using the solar cell module are provided with the above-described features, so that the following effects can be obtained. it can.

That is, in a solar cell module having an electrode take-out portion formed of a conductive member for extracting electric power from the photovoltaic element to the outside, heating in a solar cell module manufacturing process after the conductive member is attached. Since the coated conductor is coated with an organic polymer resin having a softening temperature below the temperature, (1) even if the bending process is performed at a location including the electrode portion, the electrode does not crack at that portion. The solar cell module has high performance. That is, by using the covered conductor, it is possible to obtain a conductive member which is strong in bending and does not crack.

(2) A solar cell module having excellent insulation without peeling off at the interface between the resin of the coating material and the copper foil can be obtained. In other words, due to the heating temperature in the manufacturing process of the solar cell module after attaching the conductive member, the organic polymer resin which is the coating material of the coated lead wire is softened and fused with the resin of the coating material of the solar cell module, so that the The strength is increased and no interfacial peeling occurs.

(3) Even when copper is used for a metal member or the like as an electrode, discoloration, corrosion, deterioration, and the like do not occur in copper and the resin due to the synergistic action with the resin. In particular, when EVA is used as the resin for the covering material, the covering material for the covered electric wire is interposed between the copper and the resin. Is accelerated, and copper by acetic acid, a decomposition product of EVA, is not corroded or their synergistic action does not occur. In addition, if a resin that blocks light is used as the covering material, the resin does not deteriorate due to external factors such as light.

(4) A solar cell module having good appearance with little unevenness of the electric wire. In addition, if there is a convex portion which is a protruding portion of the electric wire, the scratch resistance of the portion is reduced, but the scratch resistance can be secured uniformly on all surfaces due to the small number of irregularities. That is, in the manufacturing process of the solar cell module, the coating material is softened, so that the unevenness can be absorbed.

The organic polymer resin has a softening temperature of 200
When the temperature is not more than ° C, (5) the material is softened at a low temperature, so that the effects described in (2) and (4) can be easily obtained.

Further, since the organic polymer resin is made of a thermoplastic resin, (6) it is easily deformed by heat, so that the effect described in (4) can be further enhanced.

The organic polymer resin may be any of vinyl chloride, heat-resistant vinyl chloride, polyethylene, foamed polyethylene, polyurethane, polypropylene, polyvinylidene fluoride, polysulfone, ethylene-vinyl acetate copolymer and ethylene propylene copolymer blend. Or (7) the use of a commercially available inexpensive material as the coating resin, because it is any of natural rubber, styrene rubber, butadiene rubber, chloroprene rubber, polyethylene chlorosulfonate, and polyethylene chloride. Therefore, a low-cost conductive member can be obtained.

Further, when the heating temperature in the manufacturing process of the solar cell module is 300 ° C. or less, (8) the solar cell module can be manufactured at a relatively low temperature, so that the manufacturing apparatus can be simplified. it can. Further, the manufacturing cost can be reduced, and an inexpensive solar cell module can be obtained.

Further, the conductor part of the coated conductor is any one of soft copper, nickel, tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, and aluminum-plated soft copper. It can be used as a conductive member.

By connecting a plurality of photovoltaic elements to form a photovoltaic element module, (10) a solar cell module having a desired power generation amount can be obtained.

Further, by simultaneously sealing the photovoltaic element or the photovoltaic element module and the conductive member with a resin, (11) protection against scratches from the outside can be achieved, and sufficient insulation can be ensured. be able to.

Further, in the resin sealing step of the solar cell module, by simultaneously applying pressure and heating, (12) the manufacturing process can be simplified and the productivity is improved.

Further, by using a light-transmitting resin film as the outermost light-transmitting surface member of the solar cell module, (13) a light-weight solar cell module can be obtained, which is excellent in earthquake resistance. I have.

(14) Since the solar cell module can have flexibility, design and workability are improved.

(15) During long-term outdoor use, contamination from the outside can be prevented, and a decrease in the conversion efficiency of the solar cell module can be reduced.

Further, by providing a reinforcing plate on the rearmost side of the solar cell module, (16) it is possible to prevent the solar cell module from warping and to have rigidity, so that it can be used as a building material. Becomes

Further, by providing a resin film layer as a back surface member on the rearmost surface side of the solar cell module, (17) the solar cell module can follow a free shape and is lightweight, so that it is portable. be able to.

[0061]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a solar cell module according to the present invention will be described with reference to the drawings.

<Photovoltaic Element> A typical photovoltaic element in the solar cell module of the present invention has a structure in which a backside reflection layer, a semiconductor photoactive layer, a transparent electrode layer, and a collecting electrode are laminated on a substrate. Has become.

FIG. 2 shows an example of a photovoltaic element. FIG. 2 (a) is a plan view of the photovoltaic element, and FIG. 2 (b) is a sectional view taken along the line AA 'in FIG. 2 (a). , FIG. 2 (c) is FIG.
It is a BB 'sectional view in (a). In FIG. 2, 201 is a flexible substrate, 202 is a back reflection layer, 20
Reference numeral 3 denotes a semiconductor photoactive layer, 204 denotes a transparent electrode layer, 205 denotes a current collecting electrode, and 206 denotes a bus bar electrode.

For each member constituting the photovoltaic element,
This will be described in more detail.

As the substrate, metal, resin, glass, ceramics, semiconductor bulk and the like are used. The surface may have fine irregularities. Further, a configuration may be employed in which light is incident from the substrate side using a transparent substrate.

However, in order to maximize the flexibility of amorphous silicon, it is preferable to use a flexible substrate. That is, it is preferable to use a flexible metal or resin as the substrate. By forming metal, resin, or the like into a long shape, it is possible to cope with continuous film formation.

Examples of the material for the resin substrate include polyethylene terephthalate, polyethylene naphthalate, aromatic polyester, aromatic polyamide, polysulfonic acid, polyimide, polyarylate, polyether, and ketone.

It is more preferable to use a conductive substrate as the substrate, because it can serve as a lower electrode as well as a substrate for the photovoltaic element. Materials for the conductive substrate include silicon, tantalum, molybdenum,
Tungsten, stainless steel, aluminum, copper, titanium, carbon sheets, lead-plated steel sheets, resin films and ceramics on which conductive layers are formed, and the like can be given.

On the flexible substrate 201, the back reflection layer 20
Second, a metal layer, a metal oxide layer, or a metal layer and a metal oxide layer may be formed. Back reflection layer 20
Reference numeral 2 has a role of reflecting light reaching the flexible substrate 201 and reusing the light in the semiconductor layer.

By providing irregularities on the surface of the back reflection layer 202, the function of extending the optical path length of the reflected light in the semiconductor photoactive layer 203 and increasing the short-circuit current is achieved.

For the metal layer, for example, Ti, Cr, Mo,
W, Al, Ag, Ni, Cu, Au and the like are used, and for the metal oxide layer, for example, ZnO, TiO ₂ , SnO _{2 and the} like are used. Examples of the method for forming the metal layer and the metal oxide layer include a resistance heating evaporation method, an electron beam evaporation method, a sputtering method, plating, and printing.

The semiconductor photoactive layer 203 is a portion where photoelectric conversion is performed, and specific materials include pn junction type polycrystalline silicon, pin junction type amorphous silicon, and C
uInSe ₂ , CuInS ₂ , GaAs, CdS / Cu ₂
S, CdS / CdTe, CdS / InP, CdTe / C
Compound semiconductors such as u ₂ Te can be used. As a method of forming the semiconductor photoactive layer 203, in the case of polycrystalline silicon, a sheet of molten silicon or a heat treatment of amorphous silicon can be given. In the case of amorphous silicon, microwave plasma using silane gas or the like as a raw material can be used. CVD method, high frequency plasma CVD
In the case of a compound semiconductor, examples include ion plating, ion beam deposition, vacuum evaporation, sputtering, and electrodeposition.

Next, an apparatus and a method for forming the semiconductor photoactive layer 203 will be described.

When glass is used as the substrate, a batch processing method can be used, and when a long substrate such as stainless steel is used, a continuous processing method can be used.

In the formation of amorphous silicon, 10 to 10
Monosilane (SH ₄ ), diborane (B ₂ H ₆ ), phosphine (P) were placed in a reaction chamber maintained at a vacuum of about 10 ³ Pa.
A source gas such as H ₃ ) is introduced, and the source gas is decomposed by applying an RF electric field to form a film on a substrate such as glass or stainless steel.

The batch processing method is a method in which the reaction chamber is a single chamber and a film is formed by sequentially mixing gases. When this batch processing method is used, the film forming apparatus can be a simple apparatus, but it is inevitable that impurities remaining on the inner walls of the reaction chamber and the electrodes are mixed into the photovoltaic element. However, it is difficult to form a photovoltaic element having good characteristics with good reproducibility.

The continuous processing method is a method in which a dedicated reaction chamber is provided for each raw material gas and substrates are continuously and sequentially sent. When this continuous processing method is used, there is an advantage that the effect of residual impurities is small, a highly efficient solar cell can be formed with good reproducibility, and mass productivity is high.

The transparent electrode layer 204 functions as an upper electrode of a solar cell. Further, the transparent electrode layer 204 increases the irregular reflection of incident light and reflected light, and the semiconductor photoactive layer 2
It plays the role of extending the optical path length in 03. Also,
The transparent electrode layer 204 prevents the elements of the metal layer from diffusing or migrating into the semiconductor layer and preventing the photovoltaic element from shunting. Further, the transparent electrode layer 204
Has an appropriate resistance to prevent a short circuit due to a defect such as a pinhole in a semiconductor layer.

The transparent electrode layer 204 has a specific resistance of 10 ^−5.
(Ωcm) or more and 10 ⁻² (Ωcm) or less. Further, like the metal layer, it is preferable that the surface has irregularities.

The material used for the transparent electrode layer 204 is, for example, In ₂ O ₃ , SnO ₂ , In ₂ O ₃ -SnO.
₂ (ITO), ZnO, TiO ₂ , Cd ₂ SnO ₄ , and a crystalline semiconductor layer doped with a high concentration of impurities. Examples of the method for forming the transparent electrode layer 204 include resistance heating evaporation, sputtering, spraying, CVD, and impurity diffusion.

Since the voltage generated by one photovoltaic element is generally several volts or less, it is necessary to connect a plurality of photovoltaic elements in series during normal use. Therefore, when forming each layer as described above on the long flexible substrate 201, the photovoltaic element is divided into a certain size, and each photovoltaic element is electrically connected. They need to be connected to form a photovoltaic element module. The method of division varies depending on the size of the solar cell module and the required voltage value, and can be cut according to each use. However, on the cut surface thus cut, the photovoltaic element is crushed, and the transparent electrode layer 204 and the flexible substrate 201 are in a short-circuit state.

An amorphous silicon solar cell is
Since the film thickness is very small, there is a slight short-circuit portion inside the semiconductor photoactive layer 203. Therefore, in order to repair these short-circuits, it is necessary to provide an element isolation portion (not shown) around the transparent electrode layer 204 and remove the short-circuit around the edge of the substrate.

The removal of the short circuit is specifically performed by the following method.

First, the photovoltaic element was made of aluminum chloride 6
Immersion in an aqueous solution of 8% hydrate, the opposite electrode patterned 1 mm narrower and 1.0 mm wider than the photovoltaic element, facing the transparent electrode layer of the photovoltaic element at a distance of 1 mm from the transparent electrode layer. A 5 s, 25 A direct current was applied to form a photovoltaic element isolation part. Next, the counter electrode was replaced with a stainless steel plate electrode having the same size as the photovoltaic element, and the electrodes were faced 4.0 cm apart, and a 4.5 V bias was applied by a sequence controller to short-circuiting occurred during film formation. The portion of the transparent electrode layer is removed. Thereafter, water washing and drying are performed to form a photovoltaic element in which the short-circuit portion has been repaired.

On the transparent electrode layer 204 of the photovoltaic device thus obtained, a grid-like current collecting electrode 205 (grid) may be provided in order to efficiently collect current.

As a specific material of the current collecting electrode 205,
For example, Ti, Cr, Mo, W, Al, Ag, Ni, C
u, Sn, or a conductive paste such as a silver paste. As a method for forming the current collecting electrode 205, sputtering using a mask pattern, resistance heating, a CVD method, a method in which an unnecessary portion is removed by etching after depositing a metal film on the entire surface and patterning is performed, or a grid directly formed by photo CVD. Examples of the method include a method of forming an electrode pattern, a method of forming a mask of a negative pattern of a grid electrode pattern, followed by plating, and a method of printing a conductive paste.

The conductive paste is usually silver in the form of fine powder,
A material in which gold, copper, nickel, carbon, or the like is dispersed in a binder polymer is used. Further, examples of the binder polymer include resins such as polyester, epoxy, acrylic, alkyd, polyvinyl acetate, rubber, urethane, and phenol.

Finally, the positive bus bar electrode 206a and the negative bus bar electrode 206b are connected to the flexible substrate to extract the electromotive force from the photovoltaic element having a predetermined size obtained in this manner. Attach it to 201 and the collecting electrode 205. Negative busbar electrode 2 on flexible substrate 201
A method of attaching a metal body such as a copper tab or the like with a brazing material such as solder or the like is used to attach the 06b. The attachment of the positive bus bar electrode 206a to the current collecting electrode 205 is performed by attaching the metal body to the conductive paste 207 or the conductive paste 207. A method of electrically connecting with a brazing material is used. When the positive bus bar electrode 206a is attached to the current collecting electrode 205, an insulating material 208 is provided to prevent the positive bus bar electrode 206a from contacting the flexible substrate 201 or the semiconductor photoactive layer 203 and short-circuiting. Is preferred.

Next, a procedure for preparing a photovoltaic element module by electrically connecting the photovoltaic elements will be described with reference to FIG.

FIG. 3 shows a photovoltaic element module. FIG. 3A is a plan view seen from the light receiving surface side.
(B) is a plan view as seen from the non-light receiving surface side.

The photovoltaic elements obtained as described above are electrically connected so as to obtain a required voltage according to the purpose of use, to obtain a photovoltaic element module. If necessary, they can be connected in series or in parallel, and the series connection and the parallel connection may be mixed. In these electrical connections, as shown in FIG.
1,301 positive electrode busbar electrodes 302a and negative electrode busbar electrodes 302b are connected by a conductive member 303.

Further, the photovoltaic element module manufactured in this manner is provided with conductive members 304a and 304b for extracting electric power to the outside. Then, the photovoltaic element module provided with a conductive member for extracting electric power to the outside is sealed with a resin to form a practically usable solar cell module.

In FIG. 3, reference numeral 305 denotes a brazing material (solder) for connecting the adjacent photovoltaic elements 301, 301.

FIG. 1 shows an example of a solar cell module using the photovoltaic element module of the present invention.

As shown in FIG. 1, various materials are stacked and heated and pressed in a vacuum to obtain a solar cell module.
The heating temperature is a temperature at which the sealing resin melts and crosslinks.

In FIG. 1, 101 is a photovoltaic element module, 102 is a surface protection reinforcing material, 103 is a resin for a surface sealing material, 104 is a translucent surface member located on the outermost surface, 10
5 denotes a back surface sealing material, 106 denotes a back surface insulating material, and 107 denotes a reinforcing plate.

In this solar cell module, light from the outside enters through the translucent surface member 104 and reaches the photovoltaic element module 101, and the generated electromotive force is extracted to the outside by the conductive members 108a and 108b. It is.

When the solar cell module thus produced is installed on a roof, the solar cell module is fixed on a roof base plate using a fixing member, and the construction is performed while fixing adjacent building materials with the fixing member. .

Further, it is possible to form an array using a plurality of solar cell modules and connect a power converter to these solar cell module arrays to form a solar cell power generation system.

<Conductive Members> Next, the conductive members 303, 304a, 304b used in the solar cell module of the present invention.
Will be described.

As the conductive members 303, 304a, and 304b used in the solar cell module of the present invention, it is preferable to use covered conductors. When the solar cell module is subjected to bending processing, or when a flexible solar cell module is provided without providing a reinforcing material on the back surface, the conductive member 30
3, 304a and 304b are also subjected to various bending processes. Therefore, the conductive members 303, 304a, 30
When copper foil or the like is used as 4b, there is a problem that the copper foil is cracked by these bendings. Therefore, by using the covered conductor as the conductive members 303, 304a, and 304b, even if bending or other deformation is applied to the conductive members 303, 304a, and 304b, the conductive members 303, 304a, and 304b may not crack. Therefore, a highly reliable solar cell module can be obtained.

Further, as the shape of the covered conductor, there are a circular cross section and an elliptical cross section (flat type), and any of them may be used.

<Insulated Conductive Wire> The insulated conductive wire is required to be a low-resistance and inexpensive material. Since the conducting wire is a portion for collecting power generated by the solar cell module, a high resistance results in a large current loss. Further, as a material, it is possible to obtain a low-cost and highly reliable product by using a commonly used material. Specific materials for the conductor include soft copper, nickel,
Tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, aluminum-plated soft copper, and the like are preferable.

The shape of the conductor can be roughly classified into a single wire formed from one strand and a stranded wire formed by twisting two or more strands. In addition, in the twisting method of the stranded wire, concentric twisting of the wire core concentrically, collective twisting of thin wires collectively twisted in the same direction, and further concentric twisting of collective twisting There is a composite twist and the like. Either a single wire or a stranded wire may be used as the conductive wire.

<Coating Material of Coated Conductor> As a coating material of the covered conductor, it is preferable to use an organic polymer resin having a softening temperature equal to or lower than the heating temperature in the manufacturing process of the solar cell module. Further, a covered conductor having two or more covering layers may be used. In this case, both the inner layer and the outer layer have a softening temperature equal to or lower than the heating temperature, and each of the inner layer and the outer layer is made of a heat-resistant coating material having a high heat resistance. It may be a coated conductive wire having a double coating material layer using an organic polymer resin having a softening temperature. In particular, the outermost layer is preferably a covered conductor having a covering layer having a low softening temperature.

By the way, the softening temperature is high in all the covering materials of the covered conductor, and if the organic polymer resin of the covering material does not soften at the heating temperature in the manufacturing process of the solar cell module, the initial thickness of the covered conductor is reduced. Since the unevenness of the conductive member is used as it is, the unevenness of the conductive member is very conspicuous, and the appearance of the solar cell module deteriorates.

Further, as shown in FIG. 3, when the conductive members 304a and 304b are wired on the back side of the photovoltaic element module 301, they become convex by the thickness of the conductive members 304a and 304b, The element module 301 is deformed. In such a portion where the photovoltaic element module 301 is locally deformed, there is a concern that the reliability of the photovoltaic element may be problematic. Further, the convex portion is easily damaged because it is easily touched by an impact such as a hook from the outside, and there is a concern that this convex portion may cause a problem in reliability.

Therefore, if the softening temperature of the coating material is equal to or lower than the heating temperature in the manufacturing process of the solar cell module, the coating material is pressed in a softened state during the manufacturing process in which the thermocompression bonding is performed simultaneously. The solar cell module follows and deforms to the shape of the solar cell module, and has flatness with little unevenness.

Further, when the coating material softens, the sealing resin of the solar cell module and the resin of the coating material of the conductive members 304a and 304b are fused. For this reason, in the bent portion,
No peeling occurs at the interface between the sealing material and the coating material, and high adhesive strength can be maintained.

Specific examples of the coating material having high heat resistance include crosslinked vinyl, crosslinked polyethylene, polyethylene-tetrafluoroethylene copolymer (ETFE), polytrifluoroethylene, and polytetrafluoroethylene-hexafluoropropylene copolymer. Coalescence (FEP), polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), polyetheretherketone (PEE)
K), nylon, polyethylene terephthalate, polyimide, polyetherimide, polyethylene naphthalate, polyphenylsulfite, polymer resin such as silicon, silicone rubber, glass fiber, asbestos and the like.

Specific examples of the coating material having low heat resistance include vinyl chloride, heat-resistant vinyl chloride, polyethylene, and the like.
Polypropylene, foamed polyethylene, polyurethane, polyvinylidene fluoride (PVDF), polysulfone (P
SU), ethylene-vinyl acetate copolymer (EVA), ethylene propylene copolymer blend, natural rubber, styrene rubber, butadiene rubber, chloroprene rubber, polyethylene chlorosulfonate, polyethylene chloride, ethylene acrylate rubber, butyl rubber, etc. Molecular resins can be mentioned.

<Coating Material> Next, a coating material used for manufacturing a solar cell module will be described. Examples of the coating material used for manufacturing the solar cell module include a surface protection material, a surface sealing material, a surface protection reinforcing material, a back surface sealing material, a back surface insulating material, and a reinforcing material.

<Surface Protecting Material> As the characteristics required for the surface protecting material, it is required that the surface protecting material has translucency and weather resistance, and is hardly adhered with dirt. Examples of such a material include glass and a transparent resin film having excellent weather resistance.

Glass is an excellent material in terms of excellent translucency and weather resistance, and is excellent in protecting the photovoltaic element from scratches such as external scratches. Is preferably used.

However, especially in the case of an amorphous silicon solar cell module, a weather-resistant transparent resin film is often used in order to make use of its flexibility. When a weather-resistant transparent resin film is used, not only can the flexibility of the solar cell module be maintained, but it is also lighter, lower cost, and embossed on the film surface than glass. By applying such an effect, effects such as the surface reflection of sunlight is not dazzled are produced. Furthermore, compared to glass, it is weaker against scratches from the outside, but is stronger against shocks from the outside, and does not break like glass.

As a material for such a weather-resistant transparent resin film, a fluororesin film such as polyethylene-tetrafluoroethylene copolymer (ETFE), polytrifluoride ethylene and polyvinyl fluoride can be used. However, it is not limited to this. In addition, a surface treatment such as a corona discharge treatment can be applied to the surface to be bonded with the filler so that the filler is easily bonded.

<Surface Sealing Material> Properties required for the surface sealing material include weather resistance, thermoplasticity, heat adhesion, and light transmittance. Examples of such a material include ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer (EMA), ethylene-ethyl acrylate copolymer (EEA), butyral resin, silicone resin, and epoxy resin. A transparent resin such as a fluorinated polyimide resin can be used, but the present invention is not limited to this. Among them, EVA has well-balanced physical properties for use in solar cells, and is preferably used.

The crosslinking can be carried out by adding a crosslinking agent and a crosslinking aid to the filler. Also,
In order to suppress light deterioration, it is preferable that an ultraviolet absorber or a light stabilizer is contained.

<Surface Protection Reinforcing Material> In the case of a solar cell module whose surface is sealed with a resin and a resin film, the surface sealing material is provided in the surface sealing material in order to sufficiently protect the photovoltaic element from the outside with a small amount of resin. Contains protective reinforcement.

Specific examples of the surface protection reinforcing material include:
Fibrous inorganic compounds such as glass fiber nonwoven fabric, glass fiber woven fabric, and glass filler are effective. In particular, a glass fiber nonwoven fabric is preferred in terms of cost and performance. On the other hand, glass fiber woven fabrics are expensive and are not easily impregnated.

The use of a glass filler is ineffective in protection from the external environment, so that it is difficult to protect it with a small amount of a surface sealing material. For long-term use, it is preferable to treat the fibrous inorganic compound with a silane coupling agent or an organic titanate compound in order to ensure sufficient adhesion.

<Back Sealing Material> The back sealing material is for bonding the photovoltaic element module to the back insulating material and the back insulating material to the reinforcing material. As the material of the back surface sealing material, a material which can secure sufficient adhesiveness to a flexible substrate, has excellent long-term durability, can withstand thermal expansion and thermal contraction, and has flexibility is preferable. Materials preferably used include ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer (EMA), and ethylene-vinyl acrylate copolymer (EMA).
Ethyl acrylate copolymer (EEA), polyethylene,
Examples thereof include a hot melt material such as polyvinyl butyral, a double-sided tape, and a flexible epoxy adhesive.

In order to improve the adhesive strength between the reinforcing plate and the back surface insulating material, a tackifier resin may be applied to the surface of the adhesive. These sealing materials are often the same material as the sealing material resin used as the surface sealing material. Further, for simplifying the process, a material in which the above-mentioned adhesive layer is integrally laminated on both sides of the back surface insulating material may be used.

<Back surface insulating material> The back surface insulating material is necessary to maintain electrical insulation between the flexible substrate of the solar cell module and the outside. As the material of the back surface insulating material, a material which can secure sufficient electric insulation with a flexible substrate, has excellent long-term durability, can withstand thermal expansion and thermal contraction, and has flexibility is preferable. Suitable materials include films of nylon, polyethylene terephthalate, polycarbonate and the like.

By the way, although the electrical insulation can be maintained only by the back sealing material, the thickness tends to vary, so that the portion between the photovoltaic element and the outside is thin in a thin film portion or a pinhole portion. May cause a short circuit. To prevent such a short circuit, a back surface insulating material is used.

<Reinforcing Material> A reinforcing plate is attached to the outside of the back surface insulating material. The reinforcing plate is a member required to increase the mechanical strength of the solar cell module, prevent distortion and warpage due to temperature change, and further form a roofing integrated solar cell module. As the reinforcing plate, for example, weather resistance, painted zinc steel sheet coated with an organic polymer resin excellent in rust resistance, stainless steel sheet,
Galvalume steel plate, plated steel plate, plastic plate, FR
A P (glass fiber reinforced plastic) plate or the like is preferable.

[0127]

EXAMPLES Hereinafter, the solar cell module of the present invention will be described in more detail with reference to specific examples.

[Example 1] In the solar cell module of Example 1, first, an amorphous silicon (a-Si) solar cell (photovoltaic element) is manufactured.

<Photovoltaic Element> A procedure for manufacturing an amorphous silicon solar cell will be described with reference to FIG.

In order to manufacture an amorphous silicon solar cell, as shown in FIG. 2, an Al layer (film thickness: 5000 °) as a back reflection layer 202 is formed on a cleaned 340 mm wide coiled stainless steel substrate 201 by a sputtering method. A ZnO layer (thickness 5000 °) is sequentially formed.

Then, the SiH was formed by plasma CVD.
₄ and PH ₃ and the n-type a-Si layer from a mixed gas of H _2, Si
An i-type a-Si layer is formed from a mixed gas of H ₄ and H ₂ , and a p-type microcrystalline μc-Si layer is formed from a mixed gas of SiH ₄ , BF ₃ and H _2. 4000 / p layer thickness 100 / n layer thickness 100 / i layer thickness 800 / p
A tandem a-Si photoelectric conversion semiconductor layer 203 having a layer thickness of 100 ° is formed.

Next, as the transparent electrode layer 204, In ₂ O ₃
A thin film (thickness: 700 °) is formed by depositing In by a resistance heating method in an O ₂ atmosphere.

Next, the formed stainless steel substrate was
The photovoltaic element is cut so as to be 0 mm.

First, the photovoltaic element was made of aluminum chloride 6
Immersed in an aqueous solution of 8% hydrate, 1 m from this photovoltaic element
The counter electrode, which is 1 m wide and 1 mm wide, faces the transparent electrode layer of the photovoltaic element 1 mm away from the transparent electrode layer, and a 0.5 s, 25 A direct current is applied by a sequence controller to form a photovoltaic element separating section. I do.

Next, the counter electrode was replaced with a stainless steel plate electrode of the same size as the photovoltaic element, and was opposed 4.0 cm apart, and a bias of 4.5 V was applied by a sequence controller to generate the film at the time of film formation. The transparent electrode layer at the short-circuited portion is removed.

Thereafter, washing and drying are performed to form a photovoltaic element in which the short-circuit portion has been repaired.

Next, a current collecting electrode 205 is formed on the photovoltaic element in which the short-circuited portion has been repaired as described above. Finally, a copper tab is attached as a negative electrode bus bar electrode 206b to a stainless steel substrate using solder. As the electrode 206a, a tin foil tape is attached to the current collecting electrode 205 and used as an output terminal to obtain a photovoltaic element.

<Photovoltaic Element Module> A method of connecting the above photovoltaic elements in series to form a photovoltaic element module will be described with reference to FIG.

FIGS. 4A and 4B show the photovoltaic element module of Example 1, wherein FIG. 4A is a plan view on the light receiving surface side, and FIG. 4B is a plan view on the non-light receiving surface side.

As shown in FIG. 4, 22 photovoltaic elements 401 are prepared and arranged in a row. After that, one of the adjacent photovoltaic elements 401
The positive bus bar electrode 402a of No. 01 and the negative bus bar electrode 402b of the other photovoltaic element 401 are connected to each other by using a brazing material (solder) 405 and a covered conductor 403. Thus, the 22 photovoltaic elements 401 are serialized, and a photovoltaic element module is created.

The copper tab connected to the bus bar electrode of the photovoltaic element 401 at the end is turned on the back surface, a copper foil of an appropriate length is adhered, and the coated conductors 404a and 404b are attached to the copper foil.
And extend the wiring so that it can be taken out from one side of the photovoltaic element module.

<Coated Conductor> As the covered conductor, a covered conductor made of a vinyl chloride resin having a softening temperature of 120 ° C. and a conductor composed of a copper wire is used. The outer diameter of the conductor is 1.53
mm, the outer diameter of the covered conductor is 2.03 mm, and a stranded wire is used as the conductor.

<Modularization> A method of producing a solar cell module by covering the above photovoltaic element will be described with reference to FIG.

FIG. 5 is a schematic sectional view showing a stacked state of the solar cell module of Example 1.

As shown in FIG. 5, a photovoltaic element module 501, a surface protection reinforcing material 502, a surface sealing material 503,
Translucent surface member 504, insulating material 505 with double-sided sealing material,
A reinforcing plate 506 is prepared, and these are laminated in the order shown in FIG.

Next, the laminated body is vacuum-heated using a single vacuum laminating apparatus to produce a flat solar cell module. The vacuum condition at that time is a pumping speed of 76 To.
Evacuation is performed at rr / sec and a degree of vacuum of 5 Torr for 30 minutes. Thereafter, the laminating apparatus is put into a hot air oven at 160 ° C. and heated for 50 minutes. At this time, the sealing material resin (E
VA) is placed in an environment of 140 ° C. or more and 15 minutes or more. Thereby, EVA is melted and crosslinked.

<Surface Protection Reinforcement> Surface Protection Reinforcement 502
The basis weight is 40 g / m ² , the thickness is 200 μm, the binder acrylic resin content is 4.0%, the wire diameter is 10 μm, and the fiber length is 1.
A glass fiber nonwoven fabric of 3 mm is prepared.

<Surface Sealant> As the surface sealant 503,
A 460 μm EVA sheet prepared by mixing an ethylene-vinyl acetate copolymer (vinyl acetate 25% by weight), a crosslinking agent, an ultraviolet absorber, an antioxidant, and a light stabilizer is prepared.

<Translucent Surface Member> Translucent Surface Member 504
A non-stretched ethylene-tetrafluoroethylene film (ETFE) 50 μm is prepared. In addition, the surface in contact with the sealing material resin is subjected to plasma processing in advance.

<Insulating material with double-sided encapsulant> As the insulating material 505 with double-sided encapsulant, a formulated ethylene-vinyl acetate copolymer (vinyl acetate 25% by weight, thickness 225 μm)
And a biaxially stretched polyethylene terephthalate film (PET) (100 μm thick) as an insulating material layer,
/ PET / EVA are integrally laminated in this order to prepare an integral laminated film having a total thickness of 550 μm.

<Reinforcing Plate> As the reinforcing plate 506, a galvalume steel plate (aluminum / zinc alloy-plated steel plate in which 55% of aluminum, 43.4% of zinc, and 1.6% of silicon are integrated) and a polyester-based paint on one surface And a steel sheet coated on the other side with a polyester-based paint to which glass fiber has been added. The thickness of the steel plate is 400 μm.

<End Bending Process> A method of bending the end portion of the solar cell module manufactured as described above will be described with reference to FIG.

FIG. 6 is a perspective view of the solar cell module of Example 1 which has been bent.

Using a bender bending machine, the solar cell module 60 not including the photovoltaic element module 601 was used.
2 was bent to obtain a solar cell module 602 as shown in FIG. At this time, the bending process is performed on the photovoltaic element module 601 so that the blade or the like of the bender does not hit the portion.

In the solar cell module 602 of the first embodiment, electrodes are taken out from the ends of the solar cell module using the covered conductor. Therefore, the bending process is performed on the reinforcing material including the covered conductor, but since the covered conductor is used, there is no problem such as the conductor being cut at the bent portion.

Further, since the covered conductor is taken out from the electrode and the end, no terminal box is required on the back surface. For this reason, when installing as a roofing material, there is no need to raise the height with a pier or the like, and a roofing-material-integrated solar cell module with high workability can be obtained.

Further, between the EVA of the sealing resin and the conductor,
Since the vinyl chloride resin is interposed, the copper foil and EVA do not come into contact with each other. Therefore, since the EVA does not deteriorate or discolor, and the copper wire does not corrode, the reliability of the electrode portion can be improved.

Further, since vinyl chloride resin was used as the covered conductor, the vinyl chloride was softened and pressed under laminating conditions of 140 ° C. or more for 15 minutes. Therefore, since vinyl chloride and EVA are fused, even in the case of long-term use, vinyl chloride and EVA will be
There is no risk of peeling at the interface of In addition, 1 vinyl chloride
Since it is pressure-bonded at 40 ° C., it deforms following the shape of the solar cell module. For this reason, the unevenness of the back wiring portion of the photovoltaic element is not conspicuous, and a solar cell module excellent in aesthetic appearance can be obtained. Further, since there are no protrusions on the surface of the solar cell, the solar cell is more resistant to external impacts and the like.

Example 2 The solar cell module of Example 2 was manufactured in the same manner as in Example 1, except that a polyethylene resin (softening temperature: 105 ° C.) was used as a covering material of the coated conductor in the manufacturing process of the solar cell module of Example 1. A roofing-integrated solar cell module is produced using the same covered conductor and a similar manufacturing method.

In the solar cell module of the second embodiment, the same effect as that of the solar cell module of the first embodiment can be obtained. That is, it is possible to provide a solar cell module having good appearance without causing any breakage of the copper wire at the bent portion or peeling at the interface between polyethylene and EVA.

[Example 3] <Photovoltaic element> In the solar cell module of Example 3, a photovoltaic element is obtained in the same manner as in the solar cell module of Example 1.

<Photovoltaic Element Module> Next, the five photovoltaic elements are connected in series to form a photovoltaic element module. The series method of the photovoltaic elements is the same as that of the solar cell module of the first embodiment.

<Coated Conductor> As the covered conductor, a covered conductor composed of a vinyl chloride resin having a softening temperature of 120 ° C. and a conductor composed of a copper wire is used. The outer diameter of the conductor is 1.53
mm, the outer diameter of the covered conductor is 2.03 mm, and a stranded wire is used as the conductor.

<Modularization> A method for producing a solar cell module by covering the photovoltaic element will be described with reference to FIG.

FIG. 7 is a schematic sectional view showing a stacked state of the solar cell module of the third embodiment.

As shown in FIG. 7, a photovoltaic element module 701, a surface protection reinforcing material 702, a surface sealing material 703,
A translucent surface member 704, a back sealing material 705, and a back film 706 are prepared, and these are laminated in the order shown in FIG.

Next, the laminated body is vacuum-heated using a single vacuum laminating apparatus to produce a flat solar cell module. The vacuum condition at that time is a pumping speed of 76 To.
Evacuation is performed at rr / sec and a degree of vacuum of 5 Torr for 30 minutes. Thereafter, the laminating apparatus is put into a hot air oven at 160 ° C. and heated for 50 minutes. At this time, the sealing material resin (E
VA) is placed in an environment of 140 ° C. or more and 15 minutes or more. Thereby, EVA is melted and crosslinked.

As the respective coating materials, the same materials as those of the solar cell module of Example 1 are used.

<Back Sealing Material> As back sealing material 705,
A sheet prepared by mixing an ethylene-vinyl acetate copolymer (vinyl acetate 25% by weight), a crosslinking agent, an ultraviolet absorber, an antioxidant, and a light stabilizer in the same manner as the surface sealing material 703 is prepared. . However, the thickness is 230 μm.

<Back Film> As the back film 706, a polyvinyl fluoride (PVF) having a thickness of 50 μm is prepared.

[0171] In the solar cell module of Example 3, since no reinforcing material was provided on the back surface, a flexible solar cell module can be obtained. In addition, when carrying, it can be rolled and carried, and handling is extremely easy because of its light weight. Furthermore, it can follow the shape of the installation location.

Note that the solar cell module of Example 3
Since it is flexible, stress such as bending is applied to the series portion using the covered conductor and the electrode extraction portion. However, since the coated conductor is used, no crack is generated in these portions.

Further, since a resin that softens at the temperature of lamination is used as a covering material for the covered copper wire, it is fused with EVA to form a highly reliable solar cell module without peeling even during long-term use. be able to.

[0174]

Since the solar cell module of the present invention has the above-described configuration, the following effects can be obtained.

That is, in the solar cell module of the present invention, by using the covered conductor as the conductive member, even if the portion including the conductive member is bent, a defect such as a crack does not occur in the conductive member. In addition, it is possible to provide a solar cell module which does not cause deterioration and discoloration of the conductive wire and has high reliability even when used for a long time.

Further, by using a resin having a softening temperature equal to or lower than the heating temperature in the manufacturing process of the solar cell module as the coating material resin of the coated conductor, the unevenness of the coated conductor becomes less noticeable, and the appearance of the solar cell module is improved. become.
In addition, since the flatness of the surface can be maintained, damage from the outside is small, and the sealing material is hardly damaged, so that insulation can be secured.

Further, since both the coating resin and the sealing resin are softened and fused, the adhesive strength between them becomes extremely high, and even if a stress such as bending is applied, peeling may occur at this portion. There is no.

Further, it is possible to provide a method of manufacturing and constructing a solar cell module capable of achieving the above-described effects.

Further, it is possible to provide a solar cell power generation system using a solar cell module capable of achieving the above-described effects.

[Brief description of the drawings]

FIG. 1 is a perspective view and an enlarged sectional view of a solar cell module of the present invention.

2 (a) is a plan view, FIG. 2 (b) is a sectional view taken along the line AA ′ in FIG. 2 (a), and FIG. 2 (c) is a sectional view of B in FIG. -B 'sectional view

3A and 3B show a photovoltaic element module of the present invention for describing a conductive member, wherein FIG.
(B) is a plan view of the non-light receiving surface side

FIG. 4 shows a photovoltaic element module of Example 1,
(A) is a plan view on the light receiving surface side, and (b) is a plan view on the non-light receiving surface side.

FIG. 5 is a schematic cross-sectional view showing a stacked state of the solar cell module of Example 1.

FIG. 6 is a perspective view of the solar cell module of Example 1 which has been subjected to bending processing.

FIG. 7 is a schematic cross-sectional view showing a stacked state of the solar cell module of Example 3.

FIG. 8 is a perspective view of a conventional solar cell module viewed from a non-light-receiving surface side.

[Explanation of symbols]

101, 301, 401, 501, 601, 701 Photovoltaic element module 102, 502, 702 Surface protection reinforcing material 103, 503, 703 Surface sealing material 104, 504, 704 Translucent surface member 105, 705 Back surface sealing Material 106, 706 Back insulating material 107, 506 Reinforcement plate 108a, 304a, 404a Conductive member (covered conductor) of positive electrode side electrode lead-out part 108b, 304b, 404b Conductive member of negative electrode side electrode lead-out part (coated lead) 201 Flexibility Substrate 202 Back reflection layer 203 Semiconductor photoactive layer 204 Transparent electrode layer 205 Current collecting electrode 206a, 302a, 402a Positive bus bar electrode 206b, 302b, 402b Negative bus bar electrode 207 Conductive paste 208 Insulating layer 303, 403 Conductive member of serial part ( Covered conducting wire) 305, 405 half 505 double-sided sealing material with insulating material 602,801 solar cell module 802 terminal box 803 electrode lead wires

Continued on the front page (72) Inventor Masahiro Mori 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Meiji 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Kenji Takada 3-30-2 Shimomaruko, Ota-ku, Tokyo F-term in Canon Inc. (reference) 5F051 BA03 BA18 JA02 JA09

Claims (52)

[Claims] 1. A solar cell module having an electrode take-out portion constituted by a conductive member for deriving electric power from a photovoltaic element to the outside, wherein the conductive member is attached in a solar cell module manufacturing process after being attached. A solar cell module comprising a coated conductor covered with an organic polymer resin having a softening temperature equal to or lower than a heating temperature. 2. The solar cell module according to claim 1, wherein the organic polymer resin has a softening temperature of 200 ° C. or lower. 3. The organic polymer resin according to claim 1, wherein the organic polymer resin is made of a thermoplastic resin.
The solar cell module as described. 4. The organic polymer resin is vinyl chloride, heat-resistant vinyl chloride, polyethylene, foamed polyethylene, polyurethane, polypropylene, polyvinylidene fluoride, polysulfone, ethylene-vinyl acetate copolymer, ethylene-propylene copolymer blend. Either or
The rubber according to any one of claims 1 to 3, wherein the rubber is any one of natural rubber, styrene rubber, butadiene rubber, chloroprene rubber, polyethylene chlorosulfonate, polyethylene chloride, butyl rubber, and ethylene acrylate rubber. Solar cell module. 5. The solar cell module according to claim 1, wherein a heating temperature in a manufacturing process of the solar cell module is 300 ° C. or less. 6. The coated wire according to claim 1, wherein the conductor portion is any one of soft copper, nickel, tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, and aluminum-plated soft copper. The solar cell module according to claim 1. 7. A photovoltaic element module comprising a plurality of said photovoltaic elements connected to form a photovoltaic element module.
7. The solar cell module according to any one of 6. 8. The solar cell module according to claim 1, wherein the photovoltaic element or the photovoltaic element module and the conductive member are simultaneously sealed with a resin. 9. The solar cell module according to claim 1, wherein in the resin sealing step of the solar cell module, pressurization and heating are performed simultaneously. 10. The solar cell module according to claim 1, wherein the solar cell module uses a light-transmitting resin film as an outermost light-transmitting surface member. 11. The solar cell module according to claim 1, wherein a reinforcing plate is provided on the rearmost side of the solar cell module. 12. The solar cell module according to claim 1, wherein a resin film layer is provided as a back surface member on the most rear surface side of the solar cell module. 13. A solar cell module having a photovoltaic element module in which photovoltaic elements are connected by a conductive member, wherein the conductive member is softened to a heating temperature or lower in a manufacturing process of the solar cell module after being attached. A solar cell module comprising a coated conductor covered with an organic polymer resin having a temperature. 14. The solar cell module according to claim 13, wherein the organic polymer resin has a softening temperature of 200 ° C. or lower. 15. The solar cell module according to claim 13, wherein the organic polymer resin is made of a thermoplastic resin. 16. The organic polymer resin is vinyl chloride,
Heat-resistant polyvinyl chloride, polyethylene, foamed polyethylene, polyurethane, polypropylene, polyvinylidene fluoride,
Polysulfone, ethylene-vinyl acetate copolymer, ethylene propylene copolymer blend, or natural rubber, styrene rubber, butadiene rubber, chloroprene rubber, polyethylene chlorosulfonate, polyethylene chloride, butyl rubber, ethylene acrylate rubber The rubber is any one of rubbers.
The solar cell module according to any one of the above. 17. The solar cell module according to claim 13, wherein a heating temperature in a manufacturing process of the solar cell module is 300 ° C. or less. 18. The method according to claim 13, wherein the conductive wire portion of the coated conductive wire is any one of soft copper, nickel, tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, and aluminum-plated soft copper. Any one
Item 2. The solar cell module according to Item 1. 19. The photovoltaic element module according to claim 1, wherein a plurality of said photovoltaic elements are connected.
The solar cell module according to any one of claims 3 to 18. 20. The solar cell module according to claim 13, wherein the photovoltaic element or the photovoltaic element module and the conductive member are simultaneously resin-sealed. 21. The solar cell module according to claim 13, wherein pressurization and heating are performed simultaneously in the resin sealing step of the solar cell module. 22. The solar cell module according to claim 13, wherein the solar cell module uses a translucent resin film as the outermost translucent surface member. 23. The solar cell module according to claim 13, wherein a reinforcing plate is provided on the rearmost side of the solar cell module.
The solar cell module according to any one of the above. 24. The solar cell module according to claim 13, wherein a resin film layer is provided as a back surface member on a rearmost side of the solar cell module. 25. A method for manufacturing a solar cell module having an electrode take-out portion constituted by a conductive member for extracting electric power from a photovoltaic element to the outside, wherein the conductive member is coated with an organic polymer resin. A method for manufacturing a solar cell module, comprising a step of heating a solar cell module at a temperature equal to or higher than a softening temperature of the organic polymer resin, after using the conductive wire and attaching the coated conductive wire. 26. The method according to claim 25, wherein a resin having a softening temperature of 200 ° C. or less is used as the organic polymer resin. 27. The method for manufacturing a solar cell module according to claim 25, wherein a thermoplastic resin is used as the organic polymer resin. 28. The organic polymer resin includes vinyl chloride, heat-resistant vinyl chloride, polyethylene, foamed polyethylene, polyurethane, polypropylene, polyvinylidene fluoride, polysulfone, ethylene-vinyl acetate copolymer, and ethylene propylene copolymer blend. One of
Alternatively, natural rubber, styrene rubber, butadiene rubber,
Chloroprene rubber, polyethylene chlorosulfonate,
3. A rubber according to claim 2, wherein said rubber is selected from the group consisting of polyethylene chloride, butyl rubber, and ethylene acrylate rubber.
28. The method for manufacturing a solar cell module according to any one of items 5 to 27. 29. The method according to claim 25, wherein the heating temperature is set to 300 ° C. or lower. 30. A coated conductor having a conductor portion selected from the group consisting of soft copper, nickel, tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, and aluminum-plated soft copper. A method for manufacturing a solar cell module according to any one of claims 25 to 29. 31. The method for manufacturing a solar cell module according to claim 25, further comprising a step of connecting a plurality of said photovoltaic elements to form a photovoltaic element module. 32. The solar cell module according to claim 25, further comprising a step of resin-sealing the photovoltaic element or the photovoltaic element module and the conductive member at the same time. Production method. 33. The method for manufacturing a solar cell module according to claim 25, wherein in the resin sealing step of the solar cell module, pressurization and heating are performed simultaneously. 34. The solar cell module according to claim 25, wherein the solar cell module uses a light-transmitting resin film as the outermost light-transmitting surface member. Method. 35. The solar cell module according to claim 25, wherein a reinforcing plate is provided on the rearmost side of the solar cell module.
The method for manufacturing a solar cell module according to any one of the above. 36. The method for manufacturing a solar cell module according to claim 25, wherein a resin film layer is provided as a back surface member on the most rear surface side of the solar cell module. 37. A method of manufacturing a photovoltaic module in which a photovoltaic element is connected by a conductive member to form a photovoltaic element module, wherein the conductive member is a coated conductive wire coated with an organic polymer resin. A method for manufacturing a solar cell module, comprising a step of heating the solar cell module at a temperature equal to or higher than the softening temperature of the organic polymer resin after the conductor is attached. 38. The method according to claim 37, wherein a resin having a softening temperature of 200 ° C. or less is used as the organic polymer resin. 39. The method according to claim 37, wherein a thermoplastic resin is used as the organic polymer resin. 40. As the organic polymer resin, vinyl chloride, heat-resistant vinyl chloride, polyethylene, foamed polyethylene, polyurethane, polypropylene, polyvinylidene fluoride, polysulfone, ethylene-vinyl acetate copolymer, ethylene-propylene copolymer blend One of
Alternatively, natural rubber, styrene rubber, butadiene rubber,
Chloroprene rubber, polyethylene chlorosulfonate,
4. A rubber made of any one of polyethylene chloride, butyl rubber and ethylene acrylate rubber.
A method for manufacturing a solar cell module according to any one of claims 7 to 39. 41. The method for manufacturing a solar cell module according to claim 37, wherein the heating temperature is set to 300 ° C. or lower. 42. As the covered conductor, a covered wire having a conductor portion selected from the group consisting of soft copper, nickel, tin-plated soft copper, nickel-plated soft copper, silver-plated soft copper, aluminum, and aluminum-plated soft copper is used. A method for manufacturing a solar cell module according to any one of claims 37 to 41. 43. The method for manufacturing a solar cell module according to claim 37, further comprising a step of connecting a plurality of said photovoltaic elements to form a photovoltaic element module. 44. The solar cell module according to claim 37, further comprising a step of resin-sealing the photovoltaic element or the photovoltaic element module and the conductive member at the same time. Production method. 45. The method for manufacturing a solar cell module according to claim 37, wherein pressurization and heating are performed simultaneously in the resin sealing step of the solar cell module. 46. The solar cell module according to claim 37, wherein the solar cell module uses a translucent resin film as an outermost translucent surface member. Method. 47. A reinforcing plate is provided on the rearmost side of the solar cell module.
The method for manufacturing a solar cell module according to any one of the above. 48. The method for manufacturing a solar cell module according to claim 37, wherein a resin film layer is provided as a back surface member on the most rear surface side of the solar cell module. 49. The solar cell module according to claim 1, wherein the solar cell module is fixed on a field board with a fixing member.
A method for constructing a solar cell module, wherein adjacent building materials are fixed to each other. 50. Construction of a solar cell module, wherein the solar cell module according to any one of claims 13 to 24 is fixed on a field board by a fixing member, and adjacent building materials are fixed to each other. Method. 51. A solar cell power generation system comprising the solar cell module according to any one of claims 1 to 12 and a power converter connected to the solar cell module. 52. A solar cell power generation system comprising: the solar cell module according to claim 13; and a power converter connected to the solar cell module.